Before you do it your way, please try it our way INSTALLATION INSTRUCTIONS AND OWNERS MANUAL. Hydraulic Steering for Outboard Powered Vessels

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1 INSTALLATION INSTRUCTIONS AND OWNERS MANUAL 22 TWENTY TWO ISO 9001 MANUFACTURED BY TELEFLEX CANADA LIMITED PARTNERSHIP Hydraulic Steering for Outboard Powered Vessels Single Station steering for boats rated to a maximum of 150HP (Total). Before you do it your way, please try it our way

2 Notice to Boat Manufacturer, Installer and End User Throughout this publication, Warnings and Cautions (accompanied by the International Hazard Symbol ) are used to alert the manufacturer, and end user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe Them Carefully! These safety alerts alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the installation and maintenance, plus common sense are major accident prevention measures. DANGER Immediate hazards which WILL result in severe personal injury or death. Hazards or unsafe practices which COULD result in severe personal injury or death. CAUTION Hazards or unsafe practices which COULD result in minor injury or product or property damage. Information which is important to proper installation or maintenance, but is not hazard-related. Cleaning fluids containing ammonia, acids or any other corrosive ingredients MUST NOT be used for cleaning any part of this Hydraulic Steering System. Failure to comply will cause serious damage to the steering system, resulting in possible loss of steering, causing property damage, personal injury and/or death. Help protect your boating environment by ensuring that all used oil is disposed of properly. Don t compromise performance use genuine BayStar parts ONLY! BayStar Helms BayStar Cylinders BayStar Hoses/Tubing BayStar Oil. Substituting non BayStar parts in any part of the BayStar hydraulic steering system, may seriously compromise system performance. BAYSTAR Hydraulics

3 INTRODUCTION Before proceeding with the installation, read these instructions thoroughly. Teleflex cannot accept responsibility for installations where instructions have not been followed, where substitute parts have been used, or where modifications have been made to our products. CAUTION Do Not use BayStar on vessels that exceed a MAXIMUM horsepower rating of 150HP (Total), or on smaller HP outboard engines that use wing nut type transom mount clamping screws. Warranty will be void if combined with any other product (including SeaStar steering components). Steering failure may occur causing property damage and/or personal injury or death. BayStar is ONLY applicable for single station steering. Due to a small amount of internal hydraulic slip, a master spoke or centered steering wheel cannot be maintained with a hydraulic steering system. For best results, use an equidistant spoke steering wheel. Maximum steering wheel diameter = 28"(711mm) and Maximum steering wheel dish = 5"(127mm). Do Not use a wire coil type trim switch with a hydraulic steering system. Wire coil can wind tightly around the steering wheel shaft and prevent further steering! Index Splashwell Dimensions... ii Helm Mounting Template... 1 Horsepower Limitations... 5 Tools for Installation... 5 Helm Installation... 6 Tubing Installation... 7 Cylinder Installation HC4645H/47H/48H/58H... 9 Spacer Kit HO Reversing Compact Cylinder Engine Plate Mounting to Outboard Engines up to 60HP Filling and Purging Hydraulic Fluid Requirements Oil Level and System Check Maintenance... 2 Technical Information/Troubleshooting Replacement Parts Warranty Outboard Powered Vessels i

4 Failure to comply with maintenance checks may result in loss of steering, causing property damage, personal injury or death. Maintenance requirements will vary depending on usage. Bi-annual inspection by a qualified Marine Mechanic is required. Refer to page 24 for Maintenance instructions. BEFORE OPERATING YOUR BOAT Ensure that the following check list is carried out 1 Perform system pressure test by turning helm to hard over and then an additional 1/4 to 1/2 of a turn. This will pressurize this side of the system. Check all fittings and seals for leaks and repeat the process in the opposite direction. Repair or replace any leaking component prior to operating vessel. 2 Test the steering system. Complete two (2) full cycles with the engine being taken from hard over to hard over in both the fully tilted DOWN and fully tilted UP positions. During this operation inspect ALL moving components to ensure that no interference or restriction of mechanical components is present through the full range of travel including: NO interference between cylinder, drag link, fasteners, engine cowling, tie-bar, transom, adjustable engine lift plates, splashwell or other surfaces; NO stretching, crushing, or restriction of movement of hydraulic lines, kinking or chafing of lines against bulkhead/splashwell entry points or any other contact points. Confirm that there is no interference between the steering cylinder and the transom, splashwell or jackplate or any positional combination of these parts by performing these simple steps: Fully trim and tilt engine and turn steering from hard over to hard over while checking for interference at all positions. (If interference occurs it must be eliminated prior to operating vessel.) Confirm that the steering cylinder can be stroked fully in both directions as well as fill tilt and trim without stretching and/or kinking the hydraulic tube. Confirm that the hydraulic tubing is not subject to chaffing, kinking, pinching or stretching. Stretched, kinked or chafed tubing will fail over a period of time. Failure to comply with above instructions may result in loss of steering causing property damage, personal injury or death. Before attempting installation, ensure that the splashwell of your boat has the following minimum dimensions. Minimum Splashwell Dimensions CYLINDER # OF A B C MIN. ENGINE MODEL NUMBER ENGINES CENTER DISTANCE HC4645/47H/ 1 21" (54mm) 6" (15mm) 5" (127mm) N/A 48H/58H 2 Twin engine applications not available at this time NOTES: i) Ensure there is no interference between the BayStar cylinder rod and the splashwell boot or engine controls & cables. ii) Dimensional restrictions also apply to external motor mount brackets. iii) Ensure dimension 'A' is maintained through full trim/tilt range. iv) Maximum transom thickness "(76mm). v) Engines less than 70HP may require up to an additional 1"(25mm) of splashwell clearance. A B C ii BAYSTAR Hydraulics

5 MOUNTING TEMPLATE BayStar Helm (part# HH414 & HH4514 BayStar Plus) Scale 1:1 HELM FLANGE OUTLINE (for reference only) 4-5/8" (118mm) DIA. MAXIMUM COVERAGE, BAYSTAR HELM HH /2" (115mm) DIA. MAXIMUM COVERAGE, BAYSTAR PLUS HELM HH4514 Figure 1 Outboard Powered Vessels 1

6 Note: This page left blank intentionally. 2 BAYSTAR Hydraulics

7 SYSTEM OVERVIEW BayStar Hydraulic Steering System Maximum 150 horsepower (Total). Specific installation may vary from the application depicted. Ensure the engine can be fully tilted into the splashwell and turned from port (engine stop) to starboard (engine stop) without interference occurring between the steering cylinder and engine cowling, engine hook and the splashwell or transom. Figure 2 CAUTION Do Not use BayStar on smaller HP outboard engines that use wing nut type transom mount clamping screws. The BayStar system is a single station steering system ONLY, with the option to add an autopilot BAYSTAR CYLINDER (HC4645H SHOWN) S P BAYSTAR TUBING S P BAYSTAR HELM CYLINDER HELM PORT CONNECTION STEERING CYLINDER CONNECTION HC4645H/47H/48H/58H Port (P) Starboard side of cylinder (Cylinder is stationary) Starboard (S) Port Side of cylinder Outboard Powered Vessels

8 BAYSTAR HYDRAULIC STEERING Warranty will be void if combined with any other product. Steering Failure may occur causing property damage and/or personal injury or death. MAXIMUM 150HP (Total). BayStar Helm Pump (part# HH414) 4-5/8" (118mm) -15/16" (100mm) 7-15/16" (200mm) " dia. (76mm) Figure BayStar Cylinder (part# HC4645H/ 47H/48H/58H) 2.625" (67mm) 21" (54mm) Figure 4 4 BAYSTAR Hydraulics

9 BAYSTAR HYDRAULIC STEERING Horse Power Limitations Limited to boats rated to a MAXIMUM of 150HP (Total). Twin engine application not available at this time. Warranty void if total maximum 150HP (Total) is exceeded. Tools You will need the following tools to complete your installation. " (77mm) diameter hole saw or key hole saw 5/16" (9.5mm) drill bit Wrenches for helm installation 1/2" (1mm) for mounting the helm 5/8" (16mm) for tube nuts connecting tube to helm pump Wrenches for HC4645H/47H/48H/58H cylinder installation 9/16" (15mm) for tiller bolt (2 required) 5/8"(16mm) for shaft nuts and bleed fittings (2 required) 11/16" (18mm) for tubing on the cylinder 1-1/8" (29mm) for mounting nut CAUTION Lightly lubricate threaded fasteners before installing. This will prevent them from seizing. Lubricate support rod and all moving parts with a quality marine grease such as OMC Triple Guard, Quicksilver Anti-corrosion, Yamaha Marine Grease or equivalent. Do not remove protective caps from fittings and fitting ports until hose or tube connections are made. Contaminant's in the steering system may cause premature wear and/or steering malfunctions. Outboard Powered Vessels 5

10 MOUNTING THE HELM Use only self-locking fasteners provided; substituting non-self locking fasteners can result in loosening or separation of equipment and loss of steering control. DO NOT exceed 110 in.lbs. (12 Nm) torque on helm nuts and bolts. CAUTION Tighten steering wheel shaft nut before filling and purging the steering system. Tighten nut to 150 in./lbs. (17 Nm). DO NOT exceed 200 in.lbs. (22 Nm). Only use a pipe sealant such as Loctite P.S.T. or equivalent on ALL pipe threads. DO NOT USE "TAPE" SEALERS. Use a pipe sealant such as Loctite P.S.T. or equivalent on all pipe threads. DO NOT use "tape" sealers. Step 1: Determine desired mounting position. Ensure that the steering wheel will not interfere with other functional equipment. Check for adequate space behind the dash for fitting and line connections. Step 2: Tape the mounting template (found on page #1 of this manual) to the dash and use a center punch to mark the locations of the hole. Step : Confirm that you will not be drilling into any other equipment then; drill the diameter center hole and the four 5/16" diameter mounting holes as shown on the template. Step 4: To simplify installation, we recommend that the fittings being used in the rear of the helm pump are installed prior to the helm being mounted to the dash. See Caution at the top of page 8. Step 5: Ensuring that the fill port is in the upper position, install the four washers and four nuts onto the mounting studs of the helm pump. Torque nuts to 15 ft. lb. Step 6: Lightly grease taper of the helm shaft and mount steering wheel to helm. Figure 5 NUT WOODRUFF KEY FILL & VENT PLUG BayStar HH414 shown STEERING WHEEL HELM PUMP WASHER LOCKNUT 6 BAYSTAR Hydraulics

11 BayStar cylinders with the letter 'H' in the part number can ONLY use BayStar tube marked with H ( STEERING TUBE H). Tube Kits Hose Kits Tube nut installation and connection for BayStar tubing to helm fitting: HYDRAULIC TUBING INSTALLATION DO NOT cut and/or modify in any way the swaged fitting, protective covering or the tube at the cylinder connection end of your tube kit. Only the helm end of the TUBING without the swage fitting may be cut. If using hydraulic HOSE DO NOT CUT. Hose assemblies are NOT cut to fit. Failure to comply will cause serious damage to the steering system, resulting in possible loss of steering, causing property damage, personal injury and/or death. DO NOT remove protective fitting caps until connection of tube/ hose fitting to helm and cylinder is made. Use shortest convenient path for routing tube. Attach the cylinder end of the BayStar tubing complete with the swage fitting and protective covering the port side of the BayStar Cylinder and route tubing with a gradual rise through the Spalshwell and along the gunwale, or, through the builder installed conduit to the starboard side of the BayStar helm pump. The end of the BayStar tubing without the swage fitting and covering may be cut to fit using a proper tube or pipe cutter DO NOT use a saw. Repeat for the starboard side of the system. Leave extra tubing in the Spalshwell to allow for the cylinder rotation and motion. Attach one end of the hydraulic hose to the port side of the steering cylinder and with a gradual rise through the Splashwell and along the gunwale, or, through the builder installed conduit to the starboard side of the BayStar helm pump. DO NOT CUT the hydraulic hoses. DO NOT bend hoses tighter than 4" (10cm) radius. Repeat connection with other hose from starboard side of steering cylinder to port side in the helm pump. Prevent mix up in connections by marking both ends of one tube/hose with masking or electrical tape. Provide sufficient length to allow full uninterrupted steering motion including full trim/tilt. For HC4645H/47H/48H/58H pivot type cylinders ONLY, the tubing attached to the port side of the cylinder should attached to the starboard side of the helm pump. Tubing attached to the starboard side of the cylinder should attached to the port side of the helm pump. Slide tube nut over tubing. Push tubing into bottom of component fittings. Hand tighten tube nut, ensuring that tube is bottomed against the fitting while tightening tube nut. After hand tightening tube nut, tighten nut an additional one and a half turns with a 5/8" wrench. Cut BayStar tube with tube cutter or pipe cutter only. Thread tube fitting onto appropriate fitting on rear cover of BayStar helm and tighten to 12 ft lbs (16N.m). COMPONENT FITTING TUBE NUT BAYSTAR TUBING Figure 6 DO NOT USE PIPE SEALANT HERE Outboard Powered Vessels 7

12 BAYSTAR HYDRAULIC STEERING Figure 7 1 CAUTION 1 DO NOT adjust angle of fittings without first consulting manufacturer. 2 Tubing should be secured to the control cable harness as they enter the Splashwell through the boot. Minimum bend radius 4" (102mm). 2 Fittings inserted into the rear of the helm should be installed until finger tight and then turned an additional 1-1/2 to 2-1/2 turns depending on desired orientation of fitting. DO NOT exceed 156in/lbs (17.6Nm) BayStar tube MUST be protected from changing and any possible contact or interference with assembly screws or sharp edges of any type. The BayStar tube should be secured wherever possible. Teleflex recommends the use of a rigging tube, PVC piping or conduit for the safe secure installation of the BayStar tube. DO NOT allow the tubing to hang free in an area where they could become a safety hazard. DO NOT install tubing in such a way that they will become exposed to high heat areas such as engine manifolds or highly corrosive areas, such as battery fumes or electrical connections. Ensure that no stretching, crushing, kinking or restriction of movement, of the tubing occurs or chaffing or abrading of tube against bulkheads, Splashwell or gunwale entry points. Continuos kinking, chafing, rubbing, scoring or twisting may eventually weaken BayStar tube to a point where it could rupture from normal steering pressure causing loss of steering resulting in property damage, personal injury or death. Periodically inspect tubing and fittings for wear and/or damage. CAUTION Provide sufficient tube length to allow full, uninterrupted steering motion including trim and tilt. Ensure both elbow fittings installed in rear of helm pump, and tube nuts attaching the hydraulic tubing are installed as per the above listed instructions and are free from leaks prior to operation. Failure to comply will cause serious damage to the steering system, resulting in possible loss of steering, causing property damage, personal injury and/or death. 8 BAYSTAR Hydraulics

13 INSTALLATION INSTRUCTIONS BayStar Compact Cylinders, HC4645H, HC4647H, HC4648H and HC4658H. On the following pages of this instruction booklet you will find the assembly drawing for your specific application. Single Engines CAUTION Refer to page 24 for the correct torque specifications for your installation. Failure to correctly install your steering cylinder and torque all screws may result in steering failure causing property damage and/or personal injury. CAUTION In some cases, engine manufacturers will install plugs, caps and/or screws into the engine tiller arm. These plugs, caps and/or screws MUST be removed prior to installation of the steering cylinder. Failure to do so may cause wear on steering parts leading to property damage and/or personal injury or death. Before beginning installation make sure that all mounting hardware is included and that the tiller arm and the tilt tube bolt holes are clean and free from rust or burrs. Engines with rigid engine mounts have been shown to cause premature wear to the pivot cylinder therefore, please perform a complete Inspection of your steering system as outlined in the Maintenance Section at the back of this manual. Step 1: Using an approved quality marine grease (such as Johnson/Evinrude triple guard, Quicksilver anti-corrosion, Yamaha marine grease or equivalent), liberally lubricate the tilt tube and support rod (Item 5) and slide the support rods into the engine tilt tube. Step 2: Lightly grease the tiller bolt (Item 2) & partially screw into the appropriate hole in the tiller arm to assure a proper fit. Remove and go to Step. Step : Select appropriate insert diagram from Fig. 8 through 14 to determine proper orientation of the cylinder assembly, the tiller bolt and the self-locking nut (Items 8, 2 and 1). Grease and install as indicated. Step 4: Screw the mounting nut (Item 7) onto tilt tube of outboard engine. Step 5: Lightly grease the ends of the cylinder shaft and holes of the support rods (item 5). Attach and secure support rods (Item 5) to the cylinder shaft. Tighten using the nuts and washers (Items 4 & ) as illustrated in figure 8 through 14. If installing a jack plate make sure that there isn't any interference between the jack plate and your steering cylinder. If there is interference, it may occur during full tilt and you should install lift restrictors (Tilt Stop Switch). Some engine manufacturers supply these as standard equipment. Outboard Powered Vessels 9

14 BAYSTAR HYDRAULIC STEERING Refer to page 24 for correct torque specifications of all installation hardware. ENGINE MANUFACTURER YEAR MODEL CYLINDER NOTE FORCE 1985 TO HP HC4645H (See Fig. 8a) 1995 TO DATE HP HC4645H HONDA 1992 TO DATE 0 50 HP HC4645H Cylinder may not be centred when mounted due to short 1996 TO DATE HP HC4645H tiller tube (See Fig. 8b) 1998 TO DATE HP HC4647H (See page 1) 200 TO DATE HP HC4645H Figure 8 In some cases, engine manufacturers will install plugs, caps and/or screws into the engine tiller arm. These plugs, caps and/or screws MUST be removed prior to installation of the steering cylinder. Failure to do so may cause wear on steering parts leading to property damage and/or personal injury or death. 2* 5 7* 5 4* 4* 9 Figure 8b Figure 8a May have to cut off part of transom hangers if cylinder assembly interferes when motor is tilted to trailer lock position. Force HP 1985 to * Fully tilting the engine may cause the steering cylinder to interfere with the transom and/or splashwell. Possible damage to the steering system can result. Ensure that the cylinder is free from interference at all times. Small and mid-sized outboards, up to 60HP may use a shorter tilt tube; this will cause the cylinder to not be centered. Refer to page 19 for aligning details. * Refer to page 24 for correct torque specifications. Honda 1992 To Date 0 50 HP ITEM PART # QTY DESCRIPTION * Nut, /8" NF Nylok SS * HHCS /8" NF x 1-1/4" SS Washer Flat, 7/16" SS * /16" NF Nylok SS Support Bracket ITEM PART # QTY DESCRIPTION 6 N/A 1 Clip, Support Bracket *7 N/A 1 Mount Nut, Support Bracket H 1 Cylinder Assembly 9 HF Bleed Fitting Kit, 2 fittings per kit 10 BAYSTAR Hydraulics

15 BAYSTAR Refer to page 24 for correct torque specifications of all installation hardware. HYDRAULIC STEERING ENGINE MANUFACTURER YEAR MODEL CYLINDER NOTE HONDA 1998 TO DATE HP HC4647H Figure 9 In some cases, engine manufacturers will install plugs, caps and/or screws into the engine tiller arm. These plugs, caps and/or screws MUST be removed prior to installation of the steering cylinder. Failure to do so may cause wear on steering parts leading to property damage and/or personal injury or death. Fully tilting the engine may cause the steering cylinder to interfere with the transom and/or splashwell. Possible damage to the steering system can result. Ensure that the cylinder is free from interference at all times. Small and mid-sized outboards, up to 60HP may use a shorter tilt tube; this will cause the cylinder to not be centered. Refer to page 19 for aligning details. 2* 5 7* 5 4* 4* 6 9 1* 8 9 * Refer to page 24 for correct torque specifications. ITEM PART # QTY DESCRIPTION * Nut, /8" NF Nylok SS * HHCS /8" NF x 1-1/4" SS Washer Flat, 7/16" SS * /16" NF Nylok SS Support Bracket 6 N/A 1 Clip, Support Bracket ITEM PART # QTY DESCRIPTION *7 N/A 1 Mount Nut, Support Bracket H 1 Cylinder Assembly 9 HF Bleed Fitting Kit, 2 fittings per kit Outboard Powered Vessels 11

16 BAYSTAR HYDRAULIC STEERING Refer to page 24 for correct torque specifications of all installation hardware. ENGINE MANUFACTURER YEAR MODEL CYLINDER NOTE MERCURY/MARINER 1984-TO HP HC4645H (See Fig. 10a) 1990-TO DATE HP HC4645H 1998-TO DATE HP HC4645H Cylinder may not be centred when mounted due to short tiller tube (See Fig. 10b) 2002-TO DATE HP HC4645H (See Fig. 10c) NISSAN 1990-TO DATE HP HC4645H TOHATSU 1990-TO DATE HP HC4645H Figure 10a SPACER MAY BE REQUIRED Mercury/Mariner 1984 to 1989 Figure 10c Figure 10b Mercury 1998 to Date 40 to 60HP 2* In some cases, engine manufacturers will install plugs, caps and/or screws into the engine tiller arm. These plugs, caps and/or screws MUST be removed prior to installation of the steering cylinder. Failure to do so may cause wear on steering parts leading to property damage and/or personal injury or death. Small and mid-sized outboards, up to 60HP may use a shorter tilt tube; this will cause the cylinder to not be centered. Refer to page 19 for aligning details. 5 7* 5 4* Mercury/Mariner 2002 to Date 90 to 115HP 4* 6 9 1* 8 9 Figure 10 * Refer to page 24 for correct torque specifications. ITEM PART # QTY DESCRIPTION * Nut, /8" NF Nylok SS * HHCS /8" NF x 1-1/4" SS Washer Flat, 7/16" SS * /16" NF Nylok SS Support Bracket 6 N/A 1 Clip, Support Bracket ITEM PART # QTY DESCRIPTION *7 N/A 1 Mount Nut, Support Bracket H 1 Cylinder Assembly 9 HF Bleed Fitting Kit, 2 fittings per kit 12 BAYSTAR Hydraulics

17 Refer to page 24 for correct torque specifications of all installation hardware. BAYSTAR HYDRAULIC STEERING ENGINE MANUFACTURER YEAR MODEL CYLINDER NOTE JOHNSON/EVINRUDE 1977 TO HP HC4648H Refer to Figure 11d 1991 TO DATE HP HC4645H Refer to Figure 11a JOHNSON/EVINRUDE 1997 TO DATE 115 HP FICHT HC4658H If using cylinder HC4645H please invert pivot plate (See Page 18). Refer to Figure 11c JOHNSON/EVINRUDE 1997 TO DATE HP FICHT HC4645H 1998 TO DATE HP 4 Stroke HC4658H Requires Spacer Kit H05090 (See Page 17) If using cylinder HC4645H please invert pivot plate (See Page 18). Refer to Figure 11b Figure 11a Figure 11c Figure 11d Johnson/Evinrude 1991 to Date 40-70HP Johnson/Evinrude 1997 to Date 115 HP FICHT Johnson/Evinrude 1977 to HP Figure 11b 1* 7* 5 4* Johnson/Evinrude 1998 to Date HP 4-Stroke Figure 11 4* In some cases, engine manufacturers will install plugs, caps and/or screws into the engine tiller arm. These plugs, caps and/or screws MUST be removed prior to installation of the steering cylinder. Failure to do so may cause wear on steering parts leading to property damage and/or personal injury or death * Small and mid-sized outboards, up to 60HP may use a shorter tilt tube; this will cause the cylinder to not be centered. Refer to page 19 for aligning details. * Refer to page 24 for correct torque specifications ITEM PART # QTY DESCRIPTION * Nut, /8" NF Nylok SS * HHCS /8" NF x 1-1/4" SS Washer Flat, 7/16" SS * /16" NF Nylok SS Support Bracket ITEM PART # QTY DESCRIPTION 6 N/A 1 Clip, Support Bracket *7 N/A 1 Mount Nut, Support Bracket H 1 Cylinder Assembly 9 HF Bleed Fitting Kit, 2 fittings per kit Outboard Powered Vessels 1

18 BAYSTAR HYDRAULIC STEERING Refer to page 24 for correct torque specifications of all installation hardware. ENGINE MANUFACTURER YEAR MODEL CYLINDER NOTE YAMAHA 1998 TO DATE HP HC4645H Engine clamp brackets must be modified (cut or ground) and the engine through bolted onto transom or interference will occur restricting engine trim and tilt. (See Fig. 12a) TO DATE 60 HP HC4645H Steering Hook Yamaha Part no. 6D D must be installed and (See Fig. 12a) TO DATE HP HC4645H Requires Spacer Kit HO5090 (See Page 17) TO DATE HP 2 Stroke HC4645H 1997 TO DATE HP 4 Stroke HC4645H 200 TO DATE HP 4 Stroke HC4648H Requires Spacer Kit H05090 (See Page 17) Figure 12a Figure 12b In some cases, engine manufacturers will install plugs, caps and/or screws into the engine tiller arm. These plugs, caps and/or screws MUST be removed prior to installation of the steering cylinder. Failure to do so may cause wear on steering parts leading to property damage and/or personal injury or death. Yamaha 1998 To Date HP Yamaha 1997 To Date HP, 4 Stroke Yamaha 1986 To Date HP Yamaha 1997 To Date HP, 4 Stroke 7* 5 1* 9 5 4* 6 Figure 12 4* Engine clamp brackets must be modified (cut or ground) and the engine through bolted onto transom or interference will occur restricting engine trim & tilt. 9 2* 8 Small and mid-sized outboards, up to 60HP may use a shorter tilt tube; this will cause the cylinder to not be centered. Refer to page 19 for aligning details. * Refer to page 24 for correct torque specifications. ITEM PART # QTY DESCRIPTION * Nut, /8" NF Nylok SS * HHCS /8" NF x 1-/8" SS If spacer kit HO5090 used then: HHCS /8" NF x 1-5/8" SS (In Kit) Washer Flat, 7/16" SS * /16" NF Nylok SS Support Bracket ITEM PART # QTY DESCRIPTION 6 N/A 1 Clip, Support Bracket *7 N/A 1 Mount Nut, Support Bracket H 1 Cylinder Assembly 9 HF Bleed Fitting Kit, 2 fittings per kit 14 BAYSTAR Hydraulics

19 Refer to page 24 for correct torque specifications of all installation hardware. BAYSTAR HYDRAULIC STEERING ENGINE MANUFACTURER YEAR MODEL CYLINDER NOTE YANMAR 1990 TO DATE 27 6 HP HC4645H Requires Spacer Kit HO5090 (See Page 17). In some cases, engine manufacturers will install plugs, caps and/or screws into the engine tiller arm. These plugs, caps and/or screws MUST be removed prior to installation of the steering cylinder. Failure to do so may cause wear on steering parts leading to property damage and/or personal injury or death. Small and mid-sized outboards, up to 60HP may use a shorter tilt tube; this will cause the cylinder to not be centered. Refer to page 19 for aligning details. 1* 5 7* 5 4* 6 4* 9 9 2* 8 Figure 1 * Refer to page 24 for correct torque specifications. ITEM PART # QTY DESCRIPTION * Nut, /8" NF Nylok SS * HHCS /8" NF x 1-1/4" SS If spacer kit HO5090 used then: HHCS /8" NF x 1-5/8" SS (In Kit) Washer Flat, 7/16" SS * /16" NF Nylok SS Support Bracket ITEM PART # QTY DESCRIPTION 6 N/A 1 Clip, Support Bracket *7 N/A 1 Mount Nut, Support Bracket H 1 Cylinder Assembly 9 HF Bleed Fitting Kit, 2 fittings per kit Outboard Powered Vessels 15

20 BAYSTAR HYDRAULIC STEERING Refer to page 24 for correct torque specifications of all installation hardware. ENGINE MANUFACTURER YEAR MODEL CYLINDER NOTE SUZUKI 1986 TO DATE 150 HP HC4645H (See Fig. 14c) 1996 ONLY HP See Note Consult Factory 1987 TO HP HC4645H Requires Spacer Kit HO5090 (See Figs. 14a & 14b) 1990 TO HP HC4645H 1998 TO DATE HP 4 Stroke HC4645H Requires Spacer Kit HO5090 (See Page 17) TO DATE HP 4 Stroke HC4658H Requires Spacer Kit HO5090 (See Page 17). If using cylinder HC4645H please invert pivot plate (See Page 18). (Refer to Fig. 14d). Figure 14 Small and mid-sized outboards, up to 60HP may use a shorter tilt tube; this will cause the cylinder to not be centered. Refer to page 19 for aligning details. Figure 14a 7* 5 For ALL Suzuki HP 4 stroke use tiller bolt supplied in spacer kit HO5090. * Refer to page 24 for correct torque specifications. 1* 9 5 4* 9 Suzuki HP (use rear hole) Figure 14b May have to cut off part of transom hangers if cylinder assembly interferes when motor is tilted to trailer lock position. 4* Suzuki 115/140 to Figure 14c Suzuki 1986 to Date 150HP Figure 14d Suzuki 2001 to Date HP 4 Stroke 2* 8 Fully tilting the engine may cause the steering cylinder to interfere with the transom and/or splashwell. Possible damage to the steering system can result. Ensure that the cylinder is free from interference at all times. In some cases, engine manufacturers will install plugs, caps and/or screws into the engine tiller arm. These plugs, caps and/or screws MUST be removed prior to installation of the steering cylinder. Failure to do so may cause wear on steering parts leading to property damage and/or personal injury or death. ITEM PART # QTY DESCRIPTION * Nut, /8" NF Nylok SS * HHCS /8" NF x 1-1/4" SS If spacer kit HO5090 used then: HHCS /8" NF x 1-5/8" SS (In Kit) Washer Flat, 7/16" SS * /16" NF Nylok SS ITEM PART # QTY DESCRIPTION Support Bracket 6 N/A 1 Clip, Support Bracket *7 N/A 1 Mount Nut, Support Bracket H 1 Cylinder Assembly 9 HF Bleed Fitting Kit, 2 fittings per kit 16 BAYSTAR Hydraulics

21 HO5090 SPACER KIT For Use with Teleflex Hydraulic Steering Cylinder HC4645H, HC4647H, HC4648H and HC4658H. JOHNSON/EVINRUDE, 1998 to DATE HP 4 Stroke Fig. 15 SUZUKI 1998 to DATE HP Fig. 17 SUZUKI 2001 to DATE HP 4 Stroke Figure 15 1 Figure 17 SUZUKI 1998 to DATE 40 & 70 HP Fig Stroke 1 YAMAHA 1990 to DATE HP Fig to DATE HP 4 Stroke YANMAR 1990 to DATE 27 6 HP Fig Figure 16 Figure 18 In some cases, engine manufacturers will install plugs, caps and/or screws into the engine tiller arm. These plugs, caps and/or screws MUST be removed prior to installation of the steering cylinder. Failure to do so may cause wear on steering parts leading to property damage and/or personal injury or death. Refer to page 24 for correct torque specifications of all installation hardware. ITEM PART # QTY DESCRIPTION ITEM PART # QTY DESCRIPTION * HHCS /8" NF x 2-1/4" SS (Tiller Bolt) SS Fender Washer HHCS /8" NF x 1-/8" SS Outboard Powered Vessels 17

22 Recommended Tools: REVERSING COMPACT CYLINDER ENGINE PLATE 5/2" Allen head socket, with extension. CAUTION CAUTION 1 DO NOT attempt to reverse the pivot plate with the cylinder installed on the engine. (this may damage the steering shaft, causing irreparable damage) 2 Remove the two cap screws from one end of the steering cylinder using the 5/2" Allen head wrench, or socket. DO NOT pull the gland off the end of the shaft, doing so may damage the seals when you try to reassemble it. Remove the pivot plate and flip over end for end, placing the end hole over the shaft stub on the fixed gland. 4 After removing the cap screws there will be small amounts of debris on the screw. Ensure that any loose debris is removed from inside and the face of the cylinder body. 5 Carefully slide the loose gland back into place so that the gland stub fits into the hole on the pivot plate. Some SeaStar steering fluid applied to the O-ring on the gland may ease reinsertion into the barrel. 6 Align the screw holes on the gland with the threaded holes on the barrel, ensure that the gland face is butted tightly against the end of the barrel, with no debris in between, and fasten using the cap screws removed earlier. Tighten to torque spec 60 in-lb (5 ft-lb). Figure 19 PIVOT PLATE END GLAND BARREL SHAFT CAP SCREW 18 BAYSTAR Hydraulics

23 MOUNTING TO OUTBOARD ENGINES UP TO 60 HP Small and mid sized outboard engines up to 60HP may use a shorter tilt tube causing the BayStar Compact Steering Cylinder to be NOT centered with the engine in the straight ahead position. This will create reduced steering articulation in one direction. Please follow the instructions below to center the cylinder and address this issue. Centering Instructions: 1 Mount the steering cylinder as per your installation manual and position the engine in the straight ahead position. 2 Using a measuring tape, measure the amount of steering rod on both sides of the steering cylinders. (Refer to figure 20.) If the starboard side of the rod is shorter than the port side by 11/16" or more, proceed to Step. If less than 11/16" your cylinder is centered, continue on with steering installation as per your installation manual. Remove the support rod mounting nut (item 1), the cylinder end nut (item 2), then remove the support rod assembly. 4 Carefully remove the support rod retaining clip (item ) using a vice, and move the clip to the inner groove (item 4). 5 Reinstall the support rod assembly and verify that the measurements taken in Step 2 are now within 11/16" side to side. 6 Continue with steering system installation as per the installation manual that was provided with your steering system MEASURE THESE DISTANCES WITH MEASURING TAPE Figure 20 Outboard Powered Vessels 19

24 Read First DEALER Hydraulic Fluid Requirements NEVER use brake fluid. Any non-approved fluid may cause irreparable damage, loss of steering, and cancellation of warranty. Filling the helm with oil can be done faster if oil is poured into the helm prior to connecting filler tube and oil bottle to the helm. Part #HA548. FILLING AND PURGING THE SYSTEM Reduce purging time to approximately 10 min per system with optional, portable Power Purge Jr. For more information reference our Website at or contact Teleflex at This procedure requires two people. One person may not be able to remove all the air from the system which will result in spongy, unresponsive steering. During the entire filling procedure, oil must be visible in the filler tube. Do not allow the oil level to disappear into the helm pump, as this may introduce air into the system and increase your filling time. Recommended oils for your BayStar Steering System are; SeaStar/BayStar Marine Steering Fluid, part# HA540 (1 quart), HA5440 (1 Gallon.) Texaco HO15 Chevron Aviation Fluid A Aero Shell Fluid #41 Mobil Aero HFA Esso Univis N15 Fluids meeting Mil H5606 specifications. Automatic transmission fluid Dexron ll may be used in an emergency. In case of emergency any non-toxic, non-flammable fluid may provide temporary steering. Steering system should be fully serviced after such usage. Please contact manufacturer. Oil can be re-used if filtered through a fine mesh screen such as used for gasoline. If unable to filter oil, an additional bottle of oil is required. "Bleeder" refers to cylinder fitted with bleeder tee fittings. Open bleeder by turning bleed nipple tube nut 2 revolutions counter clockwise. Figure 21 FILLER PLUG (REMOVED) PUSH PIN FILLER KIT HELM FILL PORT DO NOT LET OIL LEVEL FALL BELOW THIS POINT Help protect your boating environment by ensuring that all used oil is disposed of properly. 20 BAYSTAR Hydraulics

25 BAYSTAR HYDRAULIC STEERING Step 1 HC4645H CYLINDER HELM OIL BOTTLE FILLER TUBE STEERING WHEEL Screw the threaded end of the filler tube into the helm filler port. Remove the cap from the oil bottle and holding upright screw into the filler tube bottle cap. Poke hole in the bottom of the bottle. Fill the helm pump with hydraulic oil so that it is visible in the filler tube. Oil should always be visible in the filler tube. Use the next bottle of fluid at any time during the procedure in order to maintain the oil level. Do not proceed with step 2 until helm is full. Step 2 TURN CLOCKWISE Turn the steering wheel counter clockwise until the cylinder rod is fully extended. Open starboard side fitting. OPEN STARBOARD SIDE BLEEDER Step TURN COUNTER- CLOCKWISE Hold the cylinder body to prevent the rod from moving and turn the wheel counter-clockwise until a steady stream of air free oil flows from the bleeder nipple. While continuing to turn the wheel, close the bleeder fitting. CLOSE STARBOARD SIDE BLEEDER Step 4 TURN COUNTER- CLOCKWISE Continue to turn the steering wheel counter-clockwise until the cylinder rod is fully extended. (Steering wheel will come to a stop) Open Port side bleeder. OPEN PORT SIDE BLEEDER Step 5 CLOSE PORT SIDE BLEEDER TURN CLOCKWISE Hold the cylinder body to prevent the rod from moving a turn the wheel clockwise until a steady stream of air free oil flows from the bleeder nipple. While continuing to turn the wheel, close the port side bleeder fitting. Outboard Powered Vessels 21

26 BAYSTAR HYDRAULIC STEERING System Air Test DO NOT use SeaStar Power Purge SR. with the BayStar Steering system unless pressure gauge kit# HA544 has been installed. Failure to do so may result in damage to the steering system. Attach the fill tube (part number HA548 page 20) to the fill port of your BayStar Helm Pump. Fill the HA548 tube approximately 1/2 with Steering fluid. Jog the steering wheel back and forth quickly approximately 1/2 turn in each direction while observing the level of fluid movement in the fill tube. If the fluid level in the filler tube remains constant, all air has been removed from the system. If the fluid level in the tube jumps more than 2 inches, further bleeding is required. When BayStar steering system has been properly purged/bled the steering wheel will turn approximately 4.5 times stop to stop. OIL LEVEL AND SYSTEM CHECK CAUTION DO NOT USE NON-VENTED FILL PLUG/CAP. CAUTION Single and twin outboard engines MUST be tested to ensure no interference occurs between the cylinder, the steerable devices, tiebars, transom, engine lift plates, splashwell or other surfaces with engine(s) at any and all combinations of hard over to hard over, highest and lowest tilt positions and engine lift plates highest and lowest adjustment. This is done by taking the system through 2 full cycles from hard over to hard over. CAUTION Failure to check for interference may result in cylinder, splashwell and/or engine damage. Check oil level prior to leaving dock or turning wheel. For helms mounted horizontally, or up to 10 from the horizontal, oil must be filled to the bottom of the fill port. DO NOT allow the oil level to drop more than 1/4" (6.mm). For helms mounted between 10 and 70 from the horizontal, oil should be maintained at between 1/8" (.2mm) and 1/2" (12.5mm) from the bottom of the fill port. Over filling may NOT allow sufficient air volume in the reservoir and may cause weeping from the vent plug. Under filling may result in air being drawn into the lines causing poor performance and/or loss of steering causing property damage, personal injury or death. At this time the steering system must be checked for proper connections of tube and fittings, possible leaks, and air removal. To do so, turn the steering wheel in one direction (port or starboard) to the engine stop position and pressurize the system by forcing the wheel beyond the engine stop position. You will not harm any component of the system by doing this. While maintaining pressure on the steering wheel, check all the fittings and tube connections for a minimum of 60 seconds for leaks. Repeat by turning the steering wheel in the opposite direction. If there is no sign of fluid loss your steering system is ready for use. If interference occurs during engine tilt or trim between steering cylinder and splashwell or jackplate, contact your engine manufacturer for trim restrictors or a Tilt Stop Switch. 22 BAYSTAR Hydraulics

27 MAINTENANCE Failure to comply with maintenance checks may result in loss of steering, causing property damage, personal injury or death. Maintenance requirements will vary depending on usage. Bi-annual inspection by a qualified Marine Mechanic is required. Remove, clean and grease the support rod annually with quality marine grease. Check the steering fluid level in the helm, it should be maintained at no less than 1/2" and no more than 1/8" below the bottom of the filler cap threads. Be careful not to overfill (Refer to Oil Level System Check on page 22). All tubing showing signs of wear MUST be replaced. Eliminate the cause of wear or re-route tubing. Check fittings & seal locations for leaks/damage and service as necessary. LUBRICATING INSTRUCTIONS GREASE SUPPORT BRACKETS, TILT TUBE, AND BRACKET ROD HOLES Figure 24, HC4645H/47H/48H/58H CAUTION Grease tilt tube, guide tube and offset link holes once a year or every 100 hours whichever comes first. Bolt Torque Specifications Values are stated in: in/lbs (N.m) These are the recommended maximum torque values for reusable dry bolts. Bolts should be torqued to this value +0% -20%. For lubricated bolts, multiply the dry bolt torque values by.75. Bolt Size 18-8SS Brass (.282) 2.0 (.226) (.8) 2.5 (.282) (.440).2 (.61) (.497).6 (.407) (.587) 4. (.486) (.740) 5.4 (.610) (.869) 6. (.712) (1.06) 7.7 (.869) Values are stated in: ft/lbs (N.m) Bolt Size 18-8SS Brass 7/16" (42.00) 26.0 (5.25) 7/16"-20.0 (44.74) 27.0 (6.61) 1/2" (58.0) 5.0 (47.45) 1/2" (61.01) 7.0 (50.17) 9/16" (77.28) 47.0 (6.72) 9/16" (85.42) 51.0 (69.15) Bolt Size 18-8SS Brass (1.08) 4.9 (.554) (1.5) 9.9 (1.12) (2.25) 16.0 (1.81) (2.48) 18.0 (2.0) (2.59) 19.0 (2.14) (.61) 26.0 (2.94) 1/4" (8.47) 62.0 (7.01) 1/4" (10.6) 77.0 (8.70) Bolt Size 18-8SS Brass 5/8" (126.09) 76.0 (10.04) 5/8" (141.00) 85.0 (115.24) /4" (17.55) (141.00) /4" (168.12) (18.29) 7/8" (26.0) (215.58) 7/8" (261.67) (214.22) Bolt Size 18-8SS Brass 5/16" (14.91) (12.10) 5/16" (16.04) (1.11) /8" (26.66) (21.71) /8" (29.20) (2.97) Bolt Size 18-8SS Brass 1" (89.12) 25.0 (18.62) 1" (51.16) (287.4) Torque values for 18-8 stainless steel and brass bolts are taken from a torque guide by ITT Harper. All results correspond well with basic bolt equations, using a bolt factor of 0.2 and a factor of /4 for a reusable connection. Outboard Powered Vessels 2

28 TROUBLE SHOOTING GUIDE Maximum 150HP (Total) Whenever in the following text a solution calls for removal from the vessel and/or dismantling of steering system components, the work must be carried out by a qualified marine hydraulic mechanic only. Teleflex Canada offers the following as a guide only and will not assume any responsibility for problems resulting from incorrect repairs. BayStar hydraulic steering will provide years of safe reliable performance with a minimum of service if properly installed with correct cylinder. BayStar steering systems have been designed with protection against over-pressure situations by a pressure relief valve. Most faults occur when the installation instructions are not followed and usually show up immediately upon filling the system. Below are the most common faults, their likely cause and solution. Sometimes when returning the wheel from a hardover position, a slight resistance may be felt and a clicking sound heard. This should not be mistaken as a fault, as it is a normal situation caused by the release of the lockspool. Warranty will be void if maximum 150HP (Total) exceeded or if combined with any other product (including SeaStar steering components). Steering failure may occur causing property damage and/or personal injury or death. FAULT CAUSE SOLUTION 1. During filling the helm becomes completely jammed. Blockage in the line between the helm and cylinder. Check ALL fittings for incomplete holes, replace faulty fitting. Fittings without complete holes, however, are not common. Make certain that the BayStar tube has not collapsed during installation. If so: In a system using tubing, the collapsed section will need to be removed and re-fitted with a new piece with the aid of tube connectors. In a system using Hose, the entire hose will need to be replaced, DO NOT cut Hose. 2. System is very difficult to fill. Air keeps burping out top of helm even after system appears full. Cylinder has been mounted upside down. This causes air to be trapped in the cylinder. Air in system. Bleed fitting leaking. Coiled BayStar tube. Mount cylinder correctly, according to cylinder installation instructions. Ports should always be kept in uppermost position. Review filling instructions. Tighten bleed fitting. Uncoil or straighten the BayStar tube.. Steering is stiff and hard to turn, even when the vessel is not moving. Restrictions in tube. Air in oil. Wrong Oil, like ATF has been sued to fill the system. Find restriction and correct. : Kinked Baystar tube MUST be replaced. Failure to do so may result in a loss of steering causing personal injury, property damage or death. See filling and purging instructions. Drain system and fill with Baystar fluid. 24 BAYSTAR Hydraulics

29 FAULT CAUSE SOLUTION 4. Helm unit in system is very bumpy and requires too many turns from hardover to hardover. Dirt in inlet check of helm pump. Dismantle check valves and remove contaminant. 5. Steering is easy to turn at the dock, but becomes hard to turn when vessel is underway. Steering wheel is too small. Incorrect setting of trim tab(s) engine. Air pocket in system. Total horsepower exceeds 150HP. Fit larger steering wheel if possible, see installation instructions. If this does not correct the problem proceed with next cause and solution or consult factory. Max. wheel dia. 22"(56cm). Adjust tab(s). Check oil level, perform air test as instructed on page 22, fill and purge system as instructed on page 20. Replace BayStar steering system with SeaStar steering system. 6. Engine drifts to port or starboard while vessel is underway, even when wheel is not being turned. Dirt in check valves. Remove check valve plugs. These are the larger SLOTTED plugs on either side on rear of helm. Clean ball seats and balls and re-assemble. Note: Be prepared to lose a certain amount of oil during this procedure. Have a small can available. Refill and purge system when check valves have been re-assembled. 7. Turning wheel to starboard causes the boat to turn to port. Incorrect tube connections. Switch the port side BayStar tubing to the starboard cylinder fitting and the starboard BayStar tubing to the port side cylinder fitting. Refill and purge system. 8. My application requires me to flip or change the pivot plate on my cylinder. Different engine applications. Please refer to page 18 for complete instructions. 9. Cylinder is not centered when installed onto engine. Small tilt tube. Remove clip and install into second groove. Please refer to page 19 for details. Outboard Powered Vessels 25

30 BAYSTAR HYDRAULIC STEERING BAYSTAR CYLINDER (PART # HC4645H, HC4647H, HC4648H, HC4658H) Maintenance/Repairs on BayStar steering components must be performed by a qualified marine mechanic. 8 9 * HF4202 is for use with BayStar Tubing marked 'H' ONLY. HF For use with NON-H tubing + Included in seal kit #HP * Figure 25 5* 2 1 ITEM PART# QTY DESCRIPTION ITEM PART# QTY DESCRIPTION Wiper Shaft Seal O-Ring O-Ring, NOT included in seal kit HP4600 *5 HF Tee Fitting Kit, comes with two + 6 complete fittings BHCS 1/4" NC x 1.5" SS Gland, Port Side Gland, Starboard Side + 9 Various 1 Pivot plat. See page 28 for your specific cylinder part number. 26 BAYSTAR Hydraulics

31 BAYSTAR HYDRAULIC STEERING REPLACEABLE PIVOT PLATE CAUTION DO NOT pull the gland off the end of the shaft, doing so may damage the seals when you try to reassemble it. CAUTION After removing the cap screws there will be small amounts of debris on the screw. Ensure that any loose debris is removed from inside and the face of the cylinder body. (PART # HA4640, HA4641, HA4642 and HA464) Remove cylinder from the engine. Please refer to page 9 before cylinder removal. Step 1 Remove the two cap screws from one end of the steering cylinder using the 5/2" Allen head wrench, or socket. Step 2 Remove the pivot plate and install the correct plate for your engine application. Step Carefully slide the loose gland back into place so that the gland stub fits into the hole on the pivot plate. Some SeaStar steering fluid applied to the O-ring on the gland may ease reinsertion into the barrel. Step 4 Align the screw holes on the gland with the threaded holes on the barrel, ensure that the gland face is butted tightly against the end of the barrel, with no debris in between, and fasten using the cap screws removed earlier. Tighten to torque spec 60 in-lb (5 ft-lb). Figure 26 HA4640 Use with cylinder HC4645H HA4641 Use with cylinder HC4647H HA4642 Use with cylinder HC4648H HA464 Use with cylinder HC4658H Figure 27, HA4640 plate shown. PIVOT PLATE END GLAND BARREL SHAFT CAP SCREW Outboard Powered Vessels 27